Suspension structure for cooling tower fill assembly



NOV. 13, 1962 5 FORDYCE r 3,063,688

SUSPENSION STRUCTURE FOR COOLING TOWER FILL ASSEMBLY Filed June 2, 1958 3 Sheets-Sheet 1 Z Arm n I N v 1962 H. E. FQRDYCE Em 3,063 688 SUSPENSION STRUCTURE FOR COOLING TOWER FILL ASSEMBLY Filed June 2, 1958 3 Sheets-Sheet 2 336 $24? if 920 film Fay 11. 7 INVENTORS Homer 5, FEM ce A TTORN K Nov. 13, 1962 o c 3,063,688

SUSPENSION STRUCTURE FOR COOLING TOWER FILL ASSEMBLY 3 Sheets-Sheet 3 Filed June 2, 1958 INVENTORS I/brd 00' 07/76 A? Ea er BY flagala United States Patent 3,063,688 SUSPENfiHQN STRUCTURE FOR CGQLENG TEBWER ASdEMELY Homer E. Fordyce, Gashiand, and Donald R. Baker,

Blue Springs, Mo assiguors to The Marley Company,

Kansas titty, Mm, a corporation of Delaware Filed June 2, E58, Ser. No, 739,961 6 (Jlainis. (Cl. 261-1(l8) This invention relates generally to the field of cooling towers of the character wherein streams of water are broken into large numbers of globules and caused to pass downwardly through a filling of splash slats as currents of are directed through the tower and into contact with the wetted splash slats and water globules.

More particularly, this invention is concerned with the provision of novel, normally horizontally spaced suspension structures adaptcd for mounting the splash sets within the tower in predetermined locations so that maximum cooling of the water is obtained and with a minimum of supporting structure for the slats being necessary.

it is the primary object of this invention to provide sus pension structure for cooling tower fill assemblies which comprises a plurality of horizontally spaced sections adapted to span the distance between and be secured to vertically spaced, horizontal frames forming a part of the tower and which sections each include a relatively rigid, preformed network of upright elements integrally interconnected by cross-member means to thereby present.

a series of polygonal openings, each adapted to receive a corresponding end of one of the splash slats to the end that the slats are maintained in predetermined spatial relationship without the necessity of providing expensive,v

intricate supporting members for such slats as has been heretofore necessary.

A further important aim or" the instant invention is to rovide suspension structure for cooling tower fill assemblies which preferably are constructed of molded, polymerized material having glass fiber strands embedded therein, whereby the structure may be produced and mounted in place on the tower at a minimum cost, the suspension structure is not subject to deterioration attributable to the moist conditions encountered in the tower, and the support structure has a very high strengthto-weight ratio, permitting the same to be relatively lightweight yet capable of supporting a large number of slats completely saturated with water.

Also an important object of this invention is to provide fill assembly suspension structure as referred to which,

in one form of the invention, comprises a plurality of horizontally spaced grids each having a series of parallel, longitudinally inc d, rectilinear elements crossed by and interconnected ith a plurality of rectilinear crossbars disposed horizontally when the section is mounted in an operable position, whereby the splash slats supported by the grid are maintained in predetermined, staggered relationship.

Other important obiects of the 'nstant in 'ention relate to the provision 0 :1 grid sus c on section as defined above, provided with cross-rods presenting loops at the uppermost end thereof adapting the same to be quickly secured to a suitable supporting frame; to the provision of a complete fill assembly utilizing the grid suspension structures heretofore described and which grids are interlocked by virtue of overlapping of proximal ends thereof, whereby the horizontal supports for the same pass through aligned openings in the sections to prevent relative vertical movement of the same; to the provision of a splash decl; assembly cooling towers wherein may be obtained any desired spacing of the splash slats without alteration of the supporting structure or framework of the tower; to the provision of novel means for maintaining and adjusting the, degree of tautness of the suspension structures after the same have been mounted in. operable positions on the tower; to the provision of foraminous supporting structures for splash slats, the character whereof precludes any loss in efliciency due to collecting or channeling of the water upon verticalparts; to the provision of suspension structure for cooling tower fill assemblies which requires no fastening means for the individual slats; and to the provision of an assembly wherein the splash slats may be easily adjusted as to position and slide to and from the operative relationship to each other.

Other objects and salient features of the instant invention will appear as the following specification progresses, particularly when referring to the accompanying drawings, wherein:

FIGURE 1 is a fragmentary, vertical, cross-sectional view through a cooling tower having suspension structure forming a part of the present invention incorporated therein and supporting a plurality of horizontal splash slats;

PEG. 2 is a fragmentary, end elevational view of the structure shown in FIG. 1;

FIG. 3 is an enlarged, fragmentary, condensed view illustrating one of the foraminous suspension structures for splash slats forming a part of the fill assembly;

FIG. 4 is an enlarged, cross-sectional view through one of the elements forming a part of the suspension structure;

FiG. 5-is an'enlarged, condensed, elevationalview showing a modified form of foraminous slat suspension structure;

PEG. 6 is a view similar to FIG. 3 showing another form of foraminous slat-supporting suspension structure;

FIG. 7 is an enlarged, cross-sectional view taken on the line 77 of FIG. 6;

F18. 8 is a view similar to FIGS. 3 and 6 showing a further modification of t re present suspension structure;

FIG. 9 is a cross-sectional view taken on the line 9-9 of FIG. 8;

PEG. 10 is a view similar to FIGS. 3, 6, and 8 illustrating a still further embodiment of the present suspension structure;

FIG. 11 is a cross-sectional view taken on the line 11-11 of FIG. 10';

FIG. 12 is a fragmentary, end elevational view of a cooling tower illustrating a further embodiment of the instant inventionand detailingsthe relative positions of the various suspension structures;

FiG. 13 is a fragmentary, vertical, cross-sectional view taken substantially on the line li -33 of RE. 12 and looking in the direction of the arrows;

FIG. 14 is an enlarged, fragmentary view of a segment of the grid section shown in elevation in PEG. 13 with the splash slats illustrated in vertical section; and

FIG. 15 is an enlarged, fragmentary, cross-sectional view through one of the joints formed by an upright element and a crossbar of the grid sections shown in FIG. 13.

The fill assembly illustrated in the, drawings and mounted within a cooling tower is particularly adapted for use in cooling water gravitating through the till by virtue of artificially produced currents of air traversing the fill assembly either in intersecting relationship to the path of travel of the water or in counterflow relationship thereto.

In accordance with the principles of FIGS. 1 to 4- of the instant invention there is provided a plurality of ,iden tical, foramino us suspension structures iii, each of which includes a pair of longitudinal, normally upright, parallel elements 12 and 14 interconnected to present elongate loops, as best seen in FIG. 1 of the drawing. The ends ofrelements 12 and Marc interconnected by cross-rods s,cea,ess

to facilitate mounting, and elements 12 and 14 are further interconnected throughout the length thereof by a number of integral loops 17 forming a pair of crossbars 16. The crossbars 16 may be formed in any desired manner, but in one form of the invention the elements 12 and 14 are looped so as to form the bars 16 integrally therewith.

Suitable frames for supporting the suspension structures are shown in FIGS. 1 to 3 inclusive and include uppermost and lowermost frames 18 and 2% respectively, that are in turn interconnected by uprights 22. Frame l3 includes a plurality of horizontal frame members 24 and the frame 20 includes a number of horizontal frame members 26 extending oppositely to frame members 24. A plurality of laterally extending, horizontal pins 28 receive the lowermost ends of the foraminous structures 1d and the opposite ends of structures ill may be secured to frame members 24 by eyebolts 34) having nuts 32 overlying frame members 24 and serving to tighten structures 1t longitudinally thereof and hold the same in a taut condition.

Structures iii are disposed to present a plurality of parallel sections 34, each of which includes a number of parallel, aligned structures 16 as shown in HG. 2, and the pins 28 may be disposed relative to the take-up means 3932 so as to incline structures 18 on their longitudinal axes. When the structures it} are so inclined, all of the crossbars 16 are disposed horizontally and, therefore, adapted to receive elongated splash slats 36 arranged in vertically staggered relationship as seen in FIG. 1 of the drawing. Such arrangement of slats 36 presents a number of horizontal splash decks which may be of equal area and which are broadly designated by the numeral .38.

In the form of the invention shown by FIGS. 1 to 4 inclusive, the structures it} are made from a suitable core 40, such as a flexible cord made from fabric, hemp or strands of glass fibers, having a coating 42 or being completely impregnated with a polymerized material such as a polyester resin. It is to be further understood that, if desired, the outer coating 42 may have suitable reinforcing material in the same in the nature of relatively short lengths of glass fibers. When structures 10 are formed as illustrated in FlG. 3 of the drawing, the elements 12 and 14 will remain substantially parallel and the crossbars 16 will be disposed in horizontal planes, while structures 10 are held taut by the supporting means 28 and 3%.

As is clear in PEG. 3, crossbars 16 are spaced so as to receive splash slats 36 in supporting relationship there to when corresponding ends of the latter are inserted into respective loops 17. This manner of supporting splash decks 38 permits disposition of slats 36 in any desired manner, but as above indicated, it is preferred that each slat 36 be offset vertically relative to the slat thereabove and therebelow and also, be olfset relative to the slats of the next adjacent sections 34-.

When the fill assembly is placed in use in a water cooling tower there is mainfestly included means for directing hot water to be cooled over decks 38 and this may either take the form of overlying spray nozzles, perforated basins, or other conventional arrangements. Similarly, there is provided and not herein shown, a water collection sump between the lowermost deck 38 for collecting cool water after the same has gravitated through the fill assembly and been subjected to the cooling action of currents of air directed horizontally through the fill from fan units or other equivalent means. The means for distributing the water onto the decks 38, for collecting such water at the lower end of the tower, as well as means for inducing the currents of air through the tower, form no part of the instant invention and therefore have not been illustrated.

By use of a suitable plastic such as a polyester resin for coatings 42 which are impregnated with suitable reinforcing means in the nature of glass fiber strands,

structures 10 are rendered long-lasting seams of resistance to deterioration by the water that constantly flows thereover, and the units have a relatively high strengthto-weight ratio. However, in FIG. 5, there is illustrated an alternate form of structure 119 in the nature of an elongated loop having the ends thereof interconnected by cross-rods and including a pair of parallel elements 112 and 114.

Elements 112 and 114 are interconnected by a plurality of crossbars 116 to form slat-receiving loops 117 and, since structures 11% are formed of material similar to structures 19, it can be recognized that crossbars 116 are integral with elements 112 and 114, such joint being indicated at 118. The suspension structures 11$ may also be formed of suitable, substantially non-corrodible metal if desired and of sufficient dimensions to provide support for the slats, even when the same are saturated with water.

In the form of the invention illustrated by FIG. 5 of the drawings, it is to be preferred that the material from which structure 11% is constructed, if the same be metal, be solid or suitably plated with a metallic coating such as stainless steel that is resistant to corrosion, and in this respect, cadmium, copper, zinc or the like have been found to be satisfactory. It is to be further noted in FIG. 5 of the drawing that the crossbars 116 may be disposed obliquely relative to elements 112 and 114 so that the same are disposed horizontally when structures 11% are mounted in place on an incline in the same manner as illustrated by PEG. 1 of the drawing.

=It is seen from the foregoing that through use of a tension type suspended fill of the nature hereinabove set forth, the entire assembly may be quickly and easily set up by simply looping the structures 10 and 110, as the case may be, over pins 23 and drawing the same tight through use of the take-up means 3tl32. Thereupon, the respective ends of slats 36 may be placed in corresponding loops of structures ltl or 116 and positioned relative to each other in any desired manner.

Furthermore, as becomes necessary from time to time, the slats 36 may be replaced without the necessity of removing any fastening means whatsoever since slats 36 are simply supported by crossbars 16 or 116 and rest loosely thereon.

Loops of suspension structure 210 illustrated in FIG. 6 of the drawings may be made from a solid, moisture resistant metal as depicted in FIG. 7 or as above explained with respect to structure 11%. In lieu of providing a pair of crossbars, one above and below each slat respectively, elements 212 and 214 are joined by a single crossbar 216 for each slat 236 respectively in the same manner as in FIG. 5.

The slat supporting structure shown in FIGS. 8 and 9 is broadly designated by the numeral 310 and may be practically produced by molding from polymerizable ma- H terial such as a polyester resin and preferably reinforced with strands of glass fibers. Structure 316 consists of a single upright element 312 having a series of cross-member means 317 defined at the upper and lower margins thereof by integral crossbars 316. It can be ascertained that cross-member means or loops 317 are of suitable dimensions to receive a corresponding end of one of the slats 336, with the lower major face of each slat 336 resting flatly on the lower cross-member 317.

Loops 317 are held against tipping in order to maintain the slats 336 transversely horizontal by substantially central disposition of element 312 relative to respective loops 317.

Structure 316 is held taut between a pair of spaced supports 318 and 320 consisting of a pin 328 on the latter receiving an eye 329 integral with rod 312. Another mounting means shown in PEG. 8 comprises the disposition of the uppermost slat 336 upon support 318 and the use of fasteners 336, if desired, attaching such slat to support 313 to hold the structure 310 against vertical shifting relative to support 318.

The modified form of the present invention shown in FIGS. and 11 may be essentially the same as that depicted by FIGS. 8 and 9. The cross-member means or loops 417 in FIGS. 10 and 11, however, are interconnected by a single, substantially upright element 410 that consists of short, diagonally disposed lengths 412. Viewing Fig. 10, it can be seen that each rod length 412 joins one lowermost corner of each loop 417 with an opposed, uppermost corner of the next loop therebelow. Such construction provides a strong, yet inexpensive, way of holding the loops 417 against tipping and maintaining slats 436 transversely horizontal.

In the preferred form of the invention illustrated in FIGS. 12 to 15 inclusive, there is provided a fill assembly broadly designated by the numeral 510 supported by framework generally numerated 512 and including upper and lower, vertically spaced frames 514 and 516 respectively, that are in turn interconnected by a plurality of uprights 518. Frame 514 includes a plurality of horizontal frame members 520 and by the same token, frame 516 has a number of horizontal frame members 522 vertically spaced from members 520.

Suspension structure for supporting a plurality of normally horizontal, transversely rectangular splash slats 536 within the cooling tower and presenting a fill assembly includes a plurality of horizontally spaced sections 524, as well as such additional sections 526 spaced below each of the sections 524 for providing support for the necessary number of splash slats 536 to produce the desired degree of cooling. Each of the sections 524 and 526 consists of a relatively rigid, preformed network of upright, parallel, longitudinally inclined, substantially rectilinear, continuous elements 528 crossed by and interconnected with a plurality of substantially rectilinear, parallel, continuous cross-bars 530, the latter being disposed at an angle with respect to elements 528 such that when sections 524 and 526 are mounted in operable positions within the cooling tower, crossbars 530 are disposed in substantially horizontal positions. As most clearly shown in FIG. 13, elements 528 and crossbars 530 define a plurality of uniformly spaced, parallelogram configured openings, certain of which are adapted to receive corresponding ends of respective splash slats 536. The number of upright elements 528 and crossbars 539 in each grid-like section 524 and 526 will depend upon the number of slats 536 necessary in the particular fill assembly, but it is to be noted that in the preferred construction, pairs of the elements 528 are disposed in proximal relationship substantially equal to the transverse width of one of the splash slats 536 whereby the lower major faces of each of the slats 536 rest flatly on a corresponding lower crossbar 539 defining a slat-receiving opening, but horizontal movement of such slats 536 is restricted by upright elements 528 disposed on each opposed edge thereof.

In order to provide means for securing each of the sections 524 and 526 to respective frames 514- or 516, a crossrod or member 532 interconnects the uppermost extremities of those elements 518 normally receiving a row of slats 536 therebetween. Any suitable securing means may be utilized to suspend sections 524- or 526 from corresponding frames 514 or 516, but in this respect it has been determined that the most satisfactory arrangement is provision of a plurality of horizontal, spaced supports 534 carried by opposed frame members 520 and 522 of frames 514- and 516 respectively. As clearly shown in FIG. 13, there is provided a support 534 for each of the openings in sections 524 and 525 defined by corresponding elements 528, crossbars 536* and cross-members 532. In this way, complete support for sections 524 and 526 is afforded with relatively inexpensive components and equal distribution of stresses on sections 524- and 526- is assured.

Another important feature of the present suspension structure is the interlocking of proximal sections 524 and 52s which is effected by virtue of the upper end of each section 526 overlapping an adjacent lower end of the section 524 thereabove so that supports 534- are received within the openings in sections 526 defined by corresponding elements 528, crossbars 530 and cross-members 532, as well as in those openings of sections 524 presented by elements 528 and crossbars 530' and in alignment with supports 534. This interlocking arrangement is most clearly illustrated in FIG. 12. and if desired, suitable, substantially J-shaped hook means 540 may be attached to respective frame members 520 and 522 and engaging proximal sections 524 and 526 for precluding relative horizontal movement of the same.

Although the relative angularity of elements 528 of each of the sections 524 and 526 with respect to crossbars 530 thereof may be varied, it is particularly contemplated that the inclination be such as to cause each of the splash slats 536 to only partially overlap the splash slat 536 thereabove as well as the slat therebefore.

Sections 524 and 526 are preferably molded of polymerizable material under relatively high pressures to thereby present a relatively rigid, unitary structure without seams and which is thereby resistant to corrosion and deterioration because of the wet conditions prevalent in the cooling tower. In order to increase the strength-toweight ratio of sections 524 and 526, elements 528 and crossbars 530 are reinforced with strands of glass fibers embedded within the polymerized material. In particular, it has been determined that by utilization of two groups 542 and 544 of strands in each of the elements 528, as well as two groups 546 and 543 of strands in crossbars 530, maximum strength characteristics are imparted to sections 524 and 526 with a minimum of materials being necessary. As clearly indicated in FIG. 15 groups 542 and 544 are intermeshed with groups 546 and 548 and all of such groups are substantially impregnated and embedded within a polymerized material 551 which may be any suitable synthetic resin having a relatively high softening point and which in the most suitable application is a conventional polyester resin. It is to be noted that the sections 524 and 526 are formed in a suitable mold under high pressures and at a curing temperature of approximately 220 F.

In order to provide maximum strength in those loops of sections 524 and 526 suspending the same from respective frames 514 and 516, it is to be pointed out that the strands of glass fibers should extend substantially uninterruptedly through cross-members 532 and the upper extremities of elements 523 which such cross-members 532 interconnect. In this manner, seams at the corners of support 534 receiving loops of sections 524 and 526 are eliminated and separation of cross-members 532 from elements 528 is substantially precluded.

'It is now apparent that through utilization of suspension structure for cooling tower fill assemblies as de scribed herein, the splash slats of such assemblies may be placed in position in the tower in a minimum of time and with little if any maintenance being necessary during the useful life of the cooling equipment. Furthermore, because of the novel means for securing the sections 524 and 525 to respective frames 514 and 516, the splash slats 536 are maintained in proper staggered, spaced relationship despite the relatively heavy weight of the same as they become saturated with water, and maximum cooling efficiency is obtained at a minimum of cost.

This application is a continuation-in-part of our application Serial No. 410,826, filed February 17, 1954 and entitled, Tension Type Suspended Fill For Cooling Towers, now abandoned.

Having thus described the invention what is claimed as new and desired to be secured by Letters Patent is:

1. A splash deck assembly for water cooling towers comprising a plurality of vertically spaced, horizontal frames; a plurality of horizontally spaced, vertical, parallel sections spanning the distance between each pair of proximal, vertically spaced frames, each section including a relatively rigid, preformed grid of corrosion resistant synthetic resin material and provided with a series of elongated, upright, parallel, continuous elements disposed at an angle with respect to the vertical and crossed by and interconnected with a plurality of elongated crossbars disposed horizontally when the section is secured to said frames, said elements and crossbars of each of the sections defining a plurality of uniformly spaced, parallelogram configured, slat-receiving openings of sutiicient size to permit the lower major faces of the slats to lie flatly on the normally lower crossbar defining a respective opening, and crossrods connecting the upper extremities of individual, spaced pairs of elements; and means carried by the frames adjacent the upper end of each of the frames for suspending the sections from respective frames, said means including a horizontal support for and received Within each series of horizontally aligned openings in the sections defined by said upper extremities of the elements and the uppermost crossrods interconnecting the same, adjacent ends of proximal, vertically spaced sections being disposed in overlapping relationship with the openings in the lower end of each overlapped section in alignment with respective supports receiving the latter to provide interlocking of said overlapped sections.

2. In suspension structure for the elongated, horizontal, transversely rectangular slats of a fill assembly forming a part of a cooling tower and thereby arranged in horizontal and upright rows, the cooling tower having a number of vertically spaced, horizontal frames above and below the fill assembly, the improvement of which comprises at least a pair of vertical, parallel, horizontally spaced sections constructed of corrosion resistant synthetic resin material and adapted to be mounted on respective pairs of proximal, vertically spaced frames, each of said sections comprising a relatively rigid, unitary, generally planar grid having a plurality of horizontally spaced, upright, elongated, parallel elements interconnected and maintained in parallel relationship by a plurality of generally horizontal, vertically spaced, elongated, parallel crossbars integral with said elements, there being a pair of elements for each of the upright rows of slats and receiving a respective upright row therehetween whereby an upright space is presented between proximal pairs of elements and devoid of slats, and there being a cross member for each of said horizontal row of slats and supporting the latter in said horizontal disposition, said elements being inclined with respect to the vertical in one direction and at a suliicie n't angle only to cause the slats to be positioned in vertically offset relationship in said upright rows thereof and with one longitudinally extending, horizontal edge of each slat overlying a centrally disposed, longitudinally extending zone of the upper surface of the slat therenext below.

3. Suspension structure as set forth in claim 2 wherein the distance between the elements of each of said pairs thereof in said sections is approximately equal to the effective Width of the slats received there-between to thereby preclude movement of the slats in respective horizontal planes.

4. Suspension structure as set forth in claim 2 wherein each of said sections is provided with a plurality of horizontally spaced, integral loop means at the upper and lower ends thereof respectively and adapted for securing the sections to corresponding frames and disposed to provide support for said sections along effective lines parallel with said elements and intersecting the longitudinal axes of said slats when the latter are positioned on respective crossbars.

5. Suspension structure as set forth in claim 2 wherein said elements and crossbars have strands of glass fiber embedded therein and extending longitudinally of the latter and substantially the full length thereof.

6. Suspension structure as set forth in claim 5 wherein the strands extending through said elements extend through respective loop means integral with the elements.

References Cited in the file of this patent UNITED STATES PATENTS 544,860 Maw Aug. 20, 1895 821,561 Wheeler et al. May 22, 1906 1,820,848 Tatum Aug. 25, 1931 2,634,959 Cave Apr. 14, 1953 "2,794,756 Leverenz June 4, 1957 FOREIGN PATENTS 496,889 Great Britain Dec. 7, 1938 585,796 Great Britain .l Feb. 25, 1947 636,173 Great Britain Apr. 26, 1950 857,376 France Apr. 15, 1940 OTHER REFERENCES Industrial and Engineering Chemistry, vol. 45, pages 1281-1286, June 1953 

